Plant Design II Guidelines (May 2015)

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GUIDELINES

CCB 4023 Plant Design II

FOR

SUPERVISORS AND STUDENTS

May 2015 Semester

CHEMICAL ENGINEERING PROGRAMME

UNIVERSITI TEKNOLOGI PETRONAS

32610 Bandar Sri Iskandar, Perak Darul Ridzuan, Malaysia

Tel: (05) 3687565 Fax: (05) 3656176

Doc. Ref. No. : UTP-ACA-PROG-PD-2

Issue Version : 2.1

Date : May, 2015

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TABLE OF CONTENTS

1.0 INTRODUCTION 1

2.0 OBJECTIVES 1

3.0 OUTCOMES 1

4.0 SCOPES 2

5.0 DURATION 2

6.0 RESPONSIBILITIES 2

6.1 Students 2

6.2 Plant Design Project Coordinator (PDPC) 3

6.3 Committee of Supervisors 4

7.0 PROCESS FLOW OF PDP II 4

8.0 FINAL REPORT 6

8.1 Format 6

8.2 Contents 9

9.0 PRESENTATIONS 18

9.1 Final Oral Presentation 18

10.0 RESOURCES AND SERVICE REQUIREMENTS 18

11.0 ASSESSMENT METHOD 19

12.0 GRADING SCHEME 19

12.1 Final Report 19

12.2 Final Oral Presentation 19

12.3 Individual Progress Performance 19

12.4 C-Factor 20

12.5 Peer Review 20

12.6 UTP Grading Scheme 20

13.0 REFERENCES 21

14.0 APPENDICES 22

Appendix I : Proposed Design Milestone 23

Appendix II : Sample title page and side labeling 24

Appendix III : Sample certification of approval 27

Appendix IV : Form PDP II-1 Requisition form 28

Appendix V : Evaluation Forms 29

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1.0 INTRODUCTION

As a continuation from Plant Design I (FYDP-I), the students need to complete Plant

Design II (FYDP-II) which carries 3 credit hours. This guideline specifically

addresses the necessary information for students/supervisors in carrying out their

duties for Plant Design II in UTP.

2.0 OBJECTIVES

The main objective of PDP II is to train/develop students in the application of all the

elements of knowledge and skills that have been accumulated throughout the

undergraduate program for solving design related problems for typical process

industrial plant. The second objective of the course is to develop the skills of working

in a team and to nurture leadership qualities. Written and oral communication skills as

well as the capability in decision making are also nurtured by the project.

3.0 OUTCOMES

At the end of this course, students should be able to:

Demonstrate their chemical engineering skills and knowledge in a detailed

design of a chemical plant.

Generate cost effective process options while maintaining operability, safety and

environment friendliness of the design.

Apply appropriate design codes in a detailed design work.

Develop a piping and instrumentation diagram (P&ID) and control strategy

package.

Prepare detailed economic evaluation of the proposed chemical plant.

Communicate and organize design group as an effective team member.

2

4.0 SCOPES OF WORK

The scopes of work for FYDP II are as follows:

Making the necessary decisions, judgements and assumptions in design

problems.

Performing the instrumentation and control study.

Performing the process design of the major process units.

Performing the mechanical design of the major process units.

Performing the economic evaluation including capital cost estimation and

manufacturing cost estimation.

Considering the environmental and safety issues related to the plant. Material

safety data sheet (MSDS) for all the chemicals involved must be part of the

safety and environmental discussion.

Utilising the blend of hand calculations, spreadsheets, mathematical computer

packages, and process simulators to design a process.

Preparing the group and individual reports as per standard format and

conducting the oral presentations.

5.0 DURATION

PDP II carries 3 credit hours and students are expected to accomplish their project in

14 weeks during the second semester of their final year. A proposed Gantt chart of

PDP II can be found in Appendix I.

6.0 RESPONSIBILITIES

6.1 Students

Students must make their own initiative and able to work in a team in bringing the

project to completion. Students will also be required to exercise teamwork spirit and

job co-ordination during undertaking the design project. The students may elect one

of their team members as the group leader. Among the expected responsibilities are as

listed below:

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Obtaining information and material rightfully and honestly. Plagiarism will

cause serious consequences.

Seeking advice and guidance from supervisors when necessary.

Maintaining good discipline and personal conduct when searching for relevant

information especially when out of campus.

Preparing themselves against any failure such as work lost due to computer

crashes.

Preparing a logbook for each member and maintain a good record of individual

activity and progress.

Undertaking the detailed design of at least one unit operation per person.

Submitting all reports on time as specified by plant design project coordinator.

Giving/putting significant individual contribution or effort towards the

completion of the group task.

Failure to take the above responsibility/responsibilities may lead to failing the course.

6.2 Plant Design Project Coordinator (PDPC)

Head of Department will appoint a Plant Design Coordinator (PDPC) and his/her

assistants to coordinate PDP II. The responsibilities of PDPC and his/her assistants

include:

Identifying and selecting design project title.

Dividing students into respective groups.

Assigning students to respective supervisors.

Planning and managing the schedule for PDP II course implementation.

Providing briefing on PDP II course requirements to lecturers and students.

Arranging special seminars in selected topics related to the project to give

additional skills to the students to complete the project.

Coordinating students' oral presentation.

Arranging external examiners from industry to participate in the assessment of

students' report and oral presentation.

Compiling and finalizing students' final scores for submission to examination

committee.

The assistants of PDPC will assist him/her in all the above activities.

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6.3 Committee of Supervisors

The committee consists of a main and with not more than two assistant supervisors.

The responsibilities of the committee can be summarized as below:

Advising the students on the preparation of their design projects.

Arranging meeting with students periodically. The supervisors are expected to

meet their students once a week.

Monitoring students’ progress from time to time.

Assisting students in defining the problem involved accordingly.

Assigning the students to undertake individual detailed calculation of mass and

energy balance.

Reviewing and assessing the individual student progress.

Assessing reports and commenting on the work.

Delivering seminar lectures on some special topics if requested by the PDPC.

7.0 PROCESS FLOW OF PDP II

The first stage of PDP II is to design the best control systems for the entire plant

proposed in PDP I. At this stage, the students need to consider the safety aspects and

provide the MSDS for all the chemicals handled in the plant. The HAZOP analysis of

major equipment together with its associated piping and minor units must also be

performed. In addition, the students are also required to specify the waste treatment

facilities and utility systems, as well as perform the equipment sizing and costing

study for the plant before presenting their work in both the final oral presentation.

After making the necessary corrections based on the comments provided during the

final oral presentation, the students are required to submit their group report using the

ring file ABBA Lever Arch Folders (404 Standard). (This submission format is made

as a strict requirement to ensure uniformity and ease of document identification and

handling as well as to facilitate the later task of storing the design reports.). The final

stage is the detailed design of equipment. Each student is expected to perform a

detailed equipment design for one major equipment including the mechanical design

and to provide the specification sheets for two minor equipment. All the individual

works have to be compiled and submitted in another ABBA Lever Arch Folders (404

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Standard). The process flow diagram of PDP II is shown in Figure 1 and the

corresponding Gantt chart can be found in Appendix I.

Process Design of Major Units

Finalized Mechanical Design of Major

Units

Specification of Minor Units

Instrumentation and Control

Safety and Loss Prevention

Waste Treatment

Process Economics & Cost Estimation

Group and Individual Report

Submission

Figure 1: Process flow diagram of PDP II

PDPII

Oral Presentation

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8.0 FINAL REPORT

8.1 Format

8.1.1 Language

The report must be written in English Language.

8.1.2 Font and spacing

All text should be one and half spacing (Times New Roman regular font style, size

12) written on a white A4 paper on one side of each sheet. The following however

should be single spaced:

Foot notes

Tables and figures

8.1.3 Length

The length of report should be not less than 100 and not more than 200 pages.

Students are strongly encouraged to use brief and straightforward expressions and to

avoid the use of jargons as far as possible. The page limit for individual design report

is limited to 40 pages per student.

8.1.4 Numbering

All pages should be numbered in proper sequence from introduction to the end of the

report. Page number must be positioned at the bottom and centered.

8.1.5 Heading and Margin

Major headings, such as INTRODUCTION, should be capitals, bold and font size

14. Secondary headings such as Example should be in bold. The top, bottom, and

right margins are 1 inch except for the left margin, which is 1.3 inch.

8.1.6 Mathematical Text

Mathematical text must be spaced out; superscript and subscript must be clearly

shown. All equations, terms and symbols must be written in italic.

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8.1.7 Tables and Figures

Tables and figures less than a page in size should be inserted into the text near the

point of reference. Tables should not be carried over to the next page. Margin limits

are the same as text full-page. All tables and figures should be numbered and

captioned consecutively. Table heading should be positioned at the top middle of each

table. The figure heading should be positioned at the bottom middle of each figure.

8.1.8 Bindings

The report must be properly presented in ABBA Lever Arch Folders (404 Standard).

Each group is required to submit two folders, i.e. group work folder and individual

work folder. Format of both group work and individual work folders are as follows:

i) Group Report

1) Title page

2) Certification – approval by main supervisor after he/she is satisfied with the

correction or amendment done by students

3) Acknowledgements

4) Executive summary – max of 4 pages + PFD. Contents should include:

a) Project summary: Briefly describe the project with information such

as:

b) Simple PFD in A3 size with major stream values

c) Material & energy balance highlights

d) Major equipment highlights with main dimensions displayed

e.g. Distillation column, Liquid extractor, reactor

e) Minor equipment highlights with brief specifications stipulated, e.g.,

heat exchangers & pumps

f) Highlights of:

Utilities

Waste treatment

Annual capacity/requirement

Main product

By product if any

Raw material 1

Raw material 2

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Economic evaluation & costs

Plant location

Plant layout

5) Table of contents

6) List of tables, figures and appendixes

7) The report must be arranged according to:

CHAPTER 1 – INTRODUCTION

CHAPTER 2 – LITERATURE REVIEW

CHAPTER 3 – CONCEPTUAL DESIGN AND SYNTHESIS

CHAPTER 4 – INSTRUMENTATION & CONTROL

CHAPTER 5 – SAFETY & LOSS PREVENTION

CHAPTER 6 – WASTE TREATMENT

CHAPTER 7 – PROCESS ECONOMICS & COST ESTIMATION

8) Conclusion & Recommendation

9) References

10) Appendices

11) PFD size A1

12) P&ID size A1

13) Plant Layout size A3

ii) Individual Report

Every member of a group needs to perform:

1) ONE (1) detailed design of major equipment

2) TWO (2) minor equipment – in specification sheets

* each group is also required to submit the final design report (both group and

individual work folders) in soft copy preferably in compact disc (CD).

* segregate each chapter with a divider.

* use punch hole protection (reinforcing ring) for every page that you wish to

submit.

* always refer to the guidelines for details.

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8.2 Contents of Group Report

8.2.1 Title Page

The title page should be set out in accordance with the attached specimen sheet in

Appendix II. The project title should be clearly and precisely defined as has been

assigned by the PDPC.

8.2.2 Certification

This section should be approved by supervisor after he/she is satisfied with the

correction or amendment done by the student. See Appendix III for specimen sheet.

8.2.3 Acknowledgements

Most design teams obtain considerable assistance and advice from supervisors,

industrial consultants, librarians, faculty and fellow students. This section provides an

opportunity to acknowledge their contributions with an expression of appreciation and

thanks.

8.2.4 Executive Summary

The students should highlight all the important features of the report from the

technical reasons for undertaking the study to the conclusion. Remember that most

readers only read the summaries of reports and every word counts. Avoid padding

phrases and phrases that refer to the reports.

8.2.5 Table of Contents

All sections in the report should be listed, including the page numbers on which they

begin. Hence, all pages in the report, without exception, must be numbered. Each

main section must begin with a new page.

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8.2.6 Main Body

The main body of the report must be composed of the following chapters:

Chapter 1: Introduction

Background of the design project, problem statement, objectives, scopes of work.

Chapter 2: Literature Review

Carry out research to uncover the latest information on feed and product properties,

product price, market, summary of potential hazards based on previous accidents and

possible site locations that may lead to a more profitable design. Literature resources

include encyclopedias, handbooks, journals, reports, indexes and even World Wide

Web (Internet). Standard method for quoting must be implemented and standardize

throughout the report.

Chapter 3: Conceptual Process Design and Synthesis

This chapter should be prepared in consultation of or based on either Douglas’

hierarchical decomposition approach or the Onion Model or a combination of both.

1. Level 1: Process Operating Mode: Batch vs. Continuous

2. Level 2: Input–Output Structure of the Flowsheet

input refers to the raw material of the process and the feedstock that

contains the input raw material

output refers to the desired products

3. Level 3: Reactor Design and Reactor Network Synthesis

Decision 1. Reactor performance:

(a) reaction scheme for the chosen process routes

(b) reactor type (flow pattern model, i.e., whether batch reactor (BR)/

plug-flow reactor (PFR) or CSTR) and

(c) reactor network (selecting conversion that maximizes selectivity

(also check the economic potential))

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Decision 2. Reactor operating conditions: (1) concentration, (2)

temperature, (3) pressure, (4) phase, (5) catalyst (inert (e.g.,

N2))

Decision 3. Reactor configuration: reactor volume (capacity of reactor i.e.,

input and output flowrates, orientation, and configuration;

some of the more common types of reactor configuration are:

tubular reactors

shell-and-tube reactors

stirred-tank reactors

fixed-bed catalytic reactors (uses catalyst)

fixed-bed noncatalytic reactors (does not use catalyst)

moving-bed catalytic reactors

fluidized-bed catalytic reactors

fluidized-bed noncatalytic reactors

kilns (e.g., used in the cement industry)

fermentor

4. Level 4: Separation System Synthesis

Decision 1. Types of separators: what type of suitable separators? (e.g.,

distillation, absorption, membrane)

Decision 2. Sequencing of separators (for homogeneous mixtures): how

are the separators arranged? (here in this course, we are

interested in sequencing of distillation columns)

Decision 3. Operating conditions: (a) temperature, (b) pressure, (c)

concentration, and (d) addition of extra components (although

undesirable)

5. Level 5: Heat Integration (Heat Exchanger Network; Heating and Cooling

Utilities):

Students are highly encouraged to use the software package SPRINT (Process

Integration Software Version 2.2 by Centre for Process Integration, University of

Manchester) to assist in the development of the heat exchanger network.

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Chapter 4: Instrumentation & Control

A basic control strategy should be performed for each stage of the process. In the

report, a summary of control requirements, possible controlled and manipulated

variables must be presented in table form. A production flowrate control strategy must

be properly mentioned. No tuning or calculation is required.

In a Piping and Instrumentation Diagram (P&ID), draw all control loops (transmitter,

controller and final elements) for the control requirements discussed in the report. No

advanced control strategy is required unless the control requirement cannot be

achieved with basic feedback control. Appropriate description must be given if

advanced control strategy is to be used.

All process equipment should be drawn roughly in proportion and identified by

equipment number. All pipes must be properly numbered. Block valve must be drawn

in small size for equipment isolation. Symbols in all drawings must follow the

PETRONAS Technical Standard (PTS).

A complete Piping and Instrumentation Diagram must be generated by using software

such Microsoft® Visio (well-recommended) or AUTOCAD (less-recommended).

Chapter 5: Safety & Loss Prevention

5.1 Hazard and Operability Studies (HAZOP)

Carry out HAZOP assessment of the specific plant area in group as specified

by supervisors. The selection should be based on the process nodes that

contain highly hazardous materials and critical process conditions identified

during preliminary hazard study. Demonstrate the HAZOP study at least for

THREE (3) study nodes, in which the nodes must connect to ONE (1) major

equipment. An appropriate HAZOP worksheet and report must be produced.

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5.2 Plant Layout

A simple but scaled plant layout arrangement for the plant should be drawn up

indicating access routes and safety appliances as well as storage / stock tanks,

silos etc. The siting criteria and layout of the plant should follow any Codes of

Practice and Industry Guidance. Students are required to provide relevant

justification/statement on the safety aspects of the plant layout.

Chapter 6: Waste Treatment

To ensure ethical and statutory requirements are fulfilled, pollution control and waste

disposal or treatment should be taken into account by referring to the process

flowsheet. All major waste must be properly identified and their flowrate and nature

(i.e., phase, characteristics, and compositions) must be defined. Appropriate

regulation limit must be stated and the treatment strategy should be proposed.

Explanation supported with basic flow diagram (or block flow diagram) that shows

the major equipment would be enough, without the need to include the auxiliary

equipment such as pumps. In other words, specific design is not required except for

sizing of the major equipment for the purpose of costing.

Chapter 7: Process Economics & Cost Estimation

Estimate capital items, operating costs and economic potential of the plant. Finally,

report the estimated return together with some recommendation as to the commercial

implications of the study. The Detailed Factorial Method with approximately 25%

accuracy must be used for detailed economic evaluation. Plant lifetime is fixed at 15

years.

(Note: Discussion needs to be included for every section starting from Chapter 3 to

Chapter 7. Explain the significance of the results, include comments and indicate

further developments.)

Conclusion & Recommendation

This section is important as it reflects the essence of the report. Hence, the highlights

from Introduction and Theory sections should be included. Do not repeat what has

been mentioned in the Discussion section.

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References

All references including sources of physical data should be listed. The following

method of referencing must be followed. In the text, refer to the work by the last

name of the author followed by the year in brackets. If there are 2 authors give the last

name of both the authors. If there are more than 2 authors give the last name of the

first author followed by et.al. In the bibliography, list all the references in alphabetical

order of the last name of the first author. All the authors must be listed as shown in

the examples below, followed by year in bracket, the name of the article or book, the

name of the journal, volume number and page number. In the case of books, the name

of the book, edition and publisher should follow the name of the author and year. For

example:

Nozhevnikova et.al (1997) has discussed the methanogenesis reactions taking place in

natural environments. Abu-Absi and Actis (1999) gave a detailed description of

different reactions taking place in an anaerobic reactor. Metcalf and Eddy (1991)

discussed the operational aspects of anaerobic reactions. Otton (1998) has presented

results on anaerobic digestion in fluidised bed reactors. Adam (2000) gave some

interesting insights into the natural anaerobic processes.

Listing of these references is as shown below.

Abu-Absi N.R., and L.A.Actis (1999), Encyclopaedia of Bioprocess Technology: Fermentation, Bio

Catalysis and Bio Separation, Vol 1, John Wiley and Sons, New York.

Adam, D. (2000), Where There is Muck There is Gas, http://www.nature.com/nsu_pf/000420-1.html

(access date)

Metcalf. C and R. Eddy (1991), Wastewater Engineering: Treatment, Disposal and Reuse, 3rd Ed. Mc-

Graw Hill Inc, New York.

Nozhevnikova, A.N., C.Hollinger, A.Amman and A.J.B Zehnder (1997), Methanogenesis in Sediments

from Deep Lakes at Different Temperatures (2-70oC), Water Science and Technology, Vol 36, No 3,

pp 384-396.

Otton, V. (1998), Anaerobic Digestion in Fluidised Bed Reactor, Thesis, Institute National

Polytechnik, Grenoble.

http://www.nature.com/nsu_pf/000420-1.html

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Appendices

Lengthy calculations, figures, results from programming, derivation of design data,

etc. should be enclosed in the appendices. Students must provide a clear explanation

and the author name for each calculation.

All drawings must be drawn on the specific paper size as follows:

a) Process Flow Diagram : A1

b) Process and Instrumentation Diagram : A1

c) Individual Equipment : A3

d) Plant Layout : A3

Drawings (a), (b) and (d) should be included in the group work folder, whereas

drawing (c) in the individual work folder. All A1 and A3 drawings should be folded

and inserted in A4 sized plastic wallets, as part of the report.

8.3 Contents of Individual Report

Based on the specified input and output, each student is required to design ONE (1)

major and TWO (2) minor equipment.

The equipment selection must follow the guideline below:

1. All groups must have a detailed design for the following equipment if present in the

flowsheet.

Major equipment:

Reactor

Distillation column

Absorption column

Furnace

2. Only one student is allowed to undertake the detailed design for each equipment.

3. The rest of the group members must be assigned to conduct two of the following

equipment if available. The supervisor may propose to PDPC if there is other major

equipment that is not listed below for detailed design.

Minor equipment:

Extraction columns

Evaporator

Membrane Units

Cyclone

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Filter

Cooling tower

Sedimentation tanks

4. If minor equipment is not available, students can conduct the detailed design of

major equipment provided it is not the same unit.

5. The individual detailed design should cater for thermal design and proper material

selection, and mechanical design in such that appropriate dimensional drawing and

complete specification sheet can be generated.

6. The rest of the equipment in the process flowsheet must be properly sized by the

group such that appropriate capital cost can be estimated. No drawing is required

for these items. However specification sheets must be provided for such units, each

student to prepare the specification sheets for two minor equipment units. The

minor units may include the following.

a. Pumps

b. Heat exchangers

c. Stirrers

d. Material conveying equipment

e. Size reduction equipment

f. Size separation equipment

g. Pollution control equipment like bag filters, electrostatic precipitators etc.

h. Waste water treatment equipment like, Sedimentation tanks, filters, ion

exchangers etc.

7. Groups may propose the responsibility of individual design. The proposal must be

approved by the supervisor.

There are six important requirements that must be fulfilled:

a) Process Design

From fundamental governing equations, carry out the process calculations to optimize

the design within specified constraints. If the design involves any assumptions, they

should be clearly stated and justified. Critical evaluation and limitations of the design

calculations, including computer methods should be included. Complete process

design calculations must be included.

b) Specification sheet

All design parameters and material selection must be properly presented in

appropriate specification sheet.

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c) Mechanical design of the equipment

The mechanical design of the equipment should include thickness of the vessel from

pressure considerations, thickness of tall vertical vessels by combined load

calculations, design of flanges, specification of nozzles, skirts, and supports.

d) Dimensional drawing

Appropriate dimensional drawing must be generated to visualize the orientation and

configuration of the unit operation. All critical parameters that directly affect the

process must be properly shown. For example, tube pitch and arrangement for heat

exchangers must be shown. All nozzles orientation must be clearly depicted.

e) Operating procedure

A basic operating procedure on how to start-up, operate and shut down the unit

operation. The shutdown procedure must include the safety aspect for carrying out

major maintenance work for the equipment.

(f) Equipment costing

You may consider making use of the graphs in the excellent process economics

textbook by Peters, Timmerhaus, and West (2004) for equipment costing. Note that

this section should be duplicated in the separate chapter on the economic

evaluation and profitability analysis of your complete plant design.

This section will contribute 20% of the final report and will be counted as

individual mark. In this section, work load distribution among group members and

equipment summary must be properly presented. For each equipment, the sizing

calculation, specification sheet, drawings and operating procedure must be compiled

together in one A4 sized plastic wallet and appropriately attached as appendix. If there

are four group members, there shall be four separate plastic wallets that contain the

complete design documents (sizing calculations, spec-sheet, drawings, and

procedures) for the respective equipment. Evaluation will be conducted as per score

sheets in Appendix V.

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9.0 PRESENTATIONS

9.1 Final Oral Presentation

This is the crucial part where students need to convince the panel on the effectiveness

and the workability/practicability of their proposed design. Students are advised to

complete their reports two weeks before the deadline and concentrate on the

presentation that is scheduled in Week 13. Presentation will be held in front of a panel

that consists of selected representatives from various fields of expertise. Each group

will be given 30 minutes for oral presentation and 30 minutes for question & answer

session. This provides sufficient time to:

introduce the design problem;

provide an overview of the proposed process (emphasising alternative designs

that were rejected);

discuss major sections of the proposed design by emphasising the strengths of

the design through: (a) the complete heat-integrated process flow diagram (PFD)

of the plant; (b) the complete piping and instrumentation diagram (P&ID) of the

plant; (c) the HAZOP analysis; (d) the design of the waste treatment facilities;

and other relevant aspects of the proposed design;

present the results of the economic analysis and discuss other considerations;

summarize the design and make recommendations.

Students who miss oral presentation will be given Grade F.

10.0 RESOURCES AND SERVICES REQUIREMENTS

Students are allowed to seek information or any sort of material needed for the project

at any institutions or other places. Application letters to Head of Programme should

be written by the students through the main supervisor. The main supervisor must fill-

up Form PDP-II (Appendix IV) and submit to PDPC together with the application

letter. All requisitions are subjected to approval of Head of Programme.

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11.0 ASSESSMENT METHOD

At the end of the semester, all students’ work will be assessed and final grade will be

given. Table 1 summarizes the overall technique of assessment.

Table 1: Assessment Scheme

Assessment Stage

Examined by and % Contribution

Supervisor Expert

Panels

External

Examiner

Group

Mark

Individual

Mark

Final Report

(Group) 10 20 30

Final Report

(Individual) 10 10 20

Final Presentation

(Group) 10 20 30

Final Presentation

(Individual) 10 10

Individual Progress 10 10

C-Factor 0 – 1.0

Total 50 30 20 60% 40%

12.0 GRADING SCHEME

12.1 Final Report

Main Supervisor and Expert Panels will evaluate the final reports (both group and

individual work folders). The percentage accounted for is shown in Table 1.

12.2 Final Oral Presentation

There are two types of assessment in the final oral presentation, namely group and

individual assessments. The percentages accounted for are shown in Table 1. Score

sheets in Appendix V will be used.

12.3 Individual Progress Performance

Each group is required to conduct an official meeting once in every two weeks. The

first official meeting must be held in the first lecture week of the semester. The last

official meeting will be held on Week 13, which will constitute a total of SEVEN (7)

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official meetings. Minutes of meeting (MOM) must be submitted to the main

supervisor within ONE (1) week after the meeting. Supervisors have to evaluate the

individual progress performance. Individual progress performance will contribute

10% of the overall individual marks. Students and supervisor may conduct additional

meetings as frequent as required.

12.4 C-Factor

C-factor is introduced to assess students on their contribution to the group work by the

supervisors. Supervisors can take the results from the peer review as a reference in

assessing the C-factor. The amount of the group mark that can be obtained by

individual is depending on the C-factor value that he/she gets.

12.5 Peer Review

Students get to evaluate among themselves through the peer review session by filling

up Form PDP II-3 (Appendix V) and return it to the Main Supervisor.

12.6 UTP Grading Scheme

The overall marks for PDP II will be finalized by PDPC after all the forms have been

completed by the examiners. The final grades will be given according to Table 2

below:

Table 2: UTP Grading Scheme

Score Grade Point

85 – 100

80 –84.9

75 – 79.9

65 – 74.9

55 – 64.9

50 – 54.9

45 – 49.9

40 – 44.9

0 – 39.9

A

A-

B+

B

C+

C

D+

D

F

4.00

3.75

3.50

3.00

2.50

2.00

1.50

1.00

0

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13. REFERENCES

Peters, Max S., Klaus D. Timmerhaus, and Ronald E. West. Plant Design and

Economics for Chemical Engineers. 5th Ed. New York: McGraw-Hill, 2004.

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APPENDICES

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Appendix I

Proposed Design Milestone

Important Dates:

Deadline for Softcopy Report Submission: 27 July (Week 11)

Tentative Dates for Final Oral Presentation: 10-14 August (Week 13)

Deadline of Final Report (After Incorporating the Changes Suggested in Final Oral Presentation) Submission: 19 August (Week 14)

PLANT DESIGN II (CCB 4023):

May Semester 2015WEEK 1 2 3 4 5 6 7 8 9 10 11 12 13 14

ACTIVITY Date 18-May 25-May 01-Jun 08-Jun 15-Jun 22-Jun 29-Jun 06-Jul 13-Jul 20-Jul 27-Jul 03-Aug 10-Aug 17-Aug

Activities

Important Dates:

Deadline for Softcopy Report Submission: 27 July (Week 11)

Tentative Date for Final Oral Presentation: 10-14 August (Week 13)

Deadline of Final Report (After Incorporating the Changes Suggested

in Final Oral Presentation) Submission: 19 August (Week 14)

Fin

al R

ep

ort

Su

bm

issi

on

Soft

cop

y o

f R

ep

ort

Sub

mis

sio

n

Fin

al O

ral

Pre

sen

tati

on

Scaled Plant Layout

Economics Evaluation: Cost Accounting and Capital Cost Estimation

Annual Costs, Earnings, and Profitability Analysis

Finalised Presentation and Reports

Instrumentation and Control Strategy P&ID

Detailed Equipment Design (Individual)

Safety and Loss Prevention

Waste Treatment

24

Appendix II

CCB 4023

PLANT DESIGN II

TITLE

GROUP 1

ZAINAL ABIDIN HASSAN 10001

CHEAH SOON KIT 10002

GOVINDARAJOO SHANTI 10003

MICHEAL BALLACK 10004

NATASHA ZVEREVA 10005

CHEMICAL ENGINEERING DEPARTMENT


MAY 2015

25

Side labeling:

Group Report

CC

B 4

023 P

LA

NT

DE

SIG

N-II

SE

ME

ST

ER

MA

Y 2

01

5

DE

SIG

N O

F X

XX

XX

X P

RO

DU

CT

ION

PL

AN

T

GR

OU

P X

X

G

RO

UP

RE

PO

RT

26

Individual Report

CC

B 4

023 P

LA

NT

DE

SIG

N-II

SE

ME

ST

ER

MA

Y 2

01

5

DE

SIG

N O

F X

XX

XX

X P

RO

DU

CT

ION

PL

AN

T

GR

OU

P X

X

IN

DIV

IDU

AL

RE

PO

RT

27

Appendix III

CCB 4023 (Plant Design II)

PLANT DESIGN PROJECT

MAY SEMESTER (2015)

TITLE

GROUP XX

ZAINAL ABIDIN HASSAN 10001

CHEAH SOON KIT 10002

GOVINDARAJOO SHANTI 10003

MICHEAL BALLACK 10004

NATASHA ZVEREVA 10005

APPROVED BY,

____________________

(DR. ROSMAN ALWI)

DATE :

CHEMICAL ENGINEERING DEPARTMENT


28

Appendix IV

Doc. Ref. No. Issue Version Date

UTP-ACA-PROG-FYPDP-01.01 0 January 2010 Form PDP II-1

REQUISITION FORM

29

Appendix V

Form PDP II-2

Assessment of Individual Group Members by Supervisors and C-FACTOR

(To be completed by Supervisor)

Group No./Name:

Project Title:

ID Name

Individual Progress

(Maximum score 10)

C-factor

(Awarded)

Assessment scheme:

Average Score Scale

7 – 10 Above expectations

4 – 6 Meet expectations

1 – 3 Below expectations

Note: C-Factor Assessment Scheme

C-Factor Awarded Scale Criteria

1.0 Average - show contribution to the group work

- satisfactory progress on the group work

- attend the official meeting

0.7 Below

Average

- no/very little contribution to the group work

- no/ very little progress on the group work

- attend the official meeting

0 Poor - no contribution to the group work

- no progress on the group work

- not attending the meeting without valid reason

…………………………

(Signature)

Supervisor’s name: Date:

30

Form PDP II-3

PEER REVIEW

CONFIDENTIAL:

(To be completed by the students and submitted to the Supervisor)

Name:

Student ID:

Group No.:

Name of Team Member Evaluation* (maximum score: 10)

Overall Evaluation

(C1 + C2 + C3 + C4 + C5)/5

C1 C2 C3 C4 C5

1.

2.

3.

4.

5.

*Criteria for evaluation:

C1: Attendance at group meetings

C2: Team work and cooperation

C3: Knowledge input to project

C4: Timely and correct completion of project

C5: Overall contribution to successful completion of project

Assessment scheme:

Average Score Scale

7 – 10 Above expectations

4 – 6 Meet expectations

1 – 3 Below expectations

Signature and name:

…………………………..

Date:

31

EVALUATION FORM PDP II – GROUP REPORT (OVERALL) FOR SUPERVISOR


Group No: ______ Project Title:

Category Excellent

(A to A-)

Good

(B+ to B)

Average

(C+ to C)

Below Average

(D+ to D)

Failure

(F)

Marks

Executive summary (20)

Inclusion of :

Background of the

design project which

stated the problem

statement and project

specifications

Objectives and scope

of the design work

required

Brief mention on

findings

Brief conclusion

State clearly all the

important and relevant

specifications for the design

problem.

Specify the work performed

and all major decisions

made throughout the design

project tasks.

Complete brief report on

the findings and conclusion.

State clearly all the relevant

specifications for the design

problem.


and decisions made while

carrying out the design

project tasks.

Complete brief report on

the findings and conclusion.

State specifications for the

design problem to some

extent.


while carrying out the

design project tasks.

Incomplete report on the

findings and conclusion.

State insufficient or non-

relevant specifications for

the design problem.

Specify some of the work

performed while carrying

out the design project tasks.

Incomplete report on the

findings and conclusion.

Did not state sufficient or

relevant specifications for

the design problem.

Did not state sufficient or

relevant work performed

while carrying out the

design project tasks.

Did not state the findings

and conclusion.

(Marks: 16-20) (Marks: 13-15.9) (Marks: 10-12.9) (Marks: 8.0-9.9) (Marks: 0.0-7.9)

Form PDP II-4

32

Category Excellent

(A to A-)

Good

(B+ to B)

Average

(C+ to C)

Below Average

(D+ to D)

Failure

(F)

Marks

Overall Design I (10)

Inclusion of :

Process Flow Diagram

with heat integration

performed

Description on Process

Flow Diagram

Stream data table to

show mass balance,

operating conditions

Economic potential

State clearly the capacity of

the plant and its feedstock.

Provide complete PFD

generated using iCON for

heat integrated flow sheet

on A1 paper. All streams

and equipment are properly

and accurately labeled and

numbered.

Provide complete

description on the process

flow.

Provide a complete stream

data table to show mass

balance and operating

conditions.

Discuss the economic

potential of the design.

State clearly the capacity of

the plant and its feedstock.

Provide incomplete PFD



on A1 paper, or with minor

errors. Streams and

equipment are labeled and

numbered with minor

errors.

Provide incomplete


flow.

Provide incomplete stream



conditions.

State briefly the economic

potential of the design.

State the capacity of the

plant and its feedstock.




on A1 paper, or with major

errors. Streams and


numbered with minor

errors.

Provide incomplete


flow, or with minor errors.




conditions, or with minor

errors.


potential of the design, with

minor errors.

State the capacity of the

plant and its feedstock.




on A1 paper, or with major

errors. Streams and


numbered with major

errors.

Provide incomplete


flow, or with major errors.




conditions, or with major

errors.


potential of the design, with

major errors.

Did not state clearly the

capacity of the plant and its

feedstock.

Do not provide PFD



on A1 paper. All streams

and equipment are not

labeled and numbered

accurately.

Do not provide description

on the process flow.

Do not provide stream data

table to show mass balance

and operating conditions.

Do not discuss the

economic potential of the

design.

(Marks: 8-10) (Marks: 6.5-7.9) (Marks: 5.0-6.4) (Marks: 4.0-4.9) (Marks: 0.0-3.9)

33

Category Excellent

(A to A-)

Good

(B+ to B)

Average

(C+ to C)

Below Average

(D+ to D)

Failure

(F)

Marks

Overall Design II (40):

Instrumentation and

Control Strategy (10)

P&ID in A1 size

Reasonable

justification on control

requirements – basic

and advanced

Appropriate

numbering of process

equipment and

pipelines

Appropriate symbols

used – PTS or other

standards

Provide reasonable and

scientific justification on

the development of

instrumentation and control

system for the process.

Clearly show technical

application of fundamental

knowledge on control

strategy with latest

literature support.

Provide a complete

summary of control

requirements for main

equipment, possible

controlled and manipulated

variables in table form.


limited scientific

justification on the

development of



Show limited technical



strategy with textbook

support.

Provide an incomplete

summary of control


equipment, possible



Provide relevant but not


the development of






strategy.


summary of control

requirements for limited

number of equipment,

possible controlled and

manipulated variables in

table form.

Provide general and limited


development of


system for the process

Show very limited or

minimum technical


knowledge.


summary of control

requirements for few

number of equipment with

minor error, possible



Lack or provide wrong


development of



Lack or show wrong

technical application of

fundamental knowledge.

Do not provide a summary

of control requirements or

with major errors, possible



Provide a PID (drawn based

on PETRONAS Technical

Standard) that clearly

shows the control system

thoroughly with technical

accuracy.



Standard) that clearly

shows the control system

with some technical

accuracy.



Standard) that do not show

the control system

thoroughly (incomplete).

Provide a PID that shows

the incomplete control

system, with some technical

errors and not according to

PETRONAS Technical

Standard.

No drawing or evidence on

the implementation of

control strategy.


34

Category Excellent

(A to A-)

Good

(B+ to B)

Average

(C+ to C)

Below Average

(D+ to D)

Failure

(F)

Marks

Safety and Loss

Prevention (10)

Reasonable selection

of study nodes for

HAZOP

Scaled plant layout in

A3 size

Reasonable

justification on safety

aspects

Appropriate standard

and symbols

Provide a report on a

complete and accurate

HAZOP analysis on

THREE (3) nodes

connected to ONE (1)

major equipment.


complete HAZOP analysis

on THREE (3) nodes


major equipment, with

minor errors.

Provide a report on an

incomplete HAZOP

analysis on THREE (3)

nodes connected to ONE

(1) major equipment, with

minor errors.


incomplete HAZOP




major errors.


HAZOP analysis.

Provide a thorough HAZOP

worksheet that clearly

shows the study results with

technical accuracy.

Provide a HAZOP

worksheet that shows the

study results with some

technical accuracy.


HAZOP worksheet that


minor technical errors.




major technical errors.

No worksheet or evidence

on the implementation of

HAZOP study.

Provide a complete and

scaled plant layout

arrangement with access

routes and safety

appliances, following

Codes of Practice and

Industry Guidance.


practical

justification/statement on

the safety aspects of the

plant layout.

Provide a scaled plant

layout arrangement with

access routes and safety



Industry Guidance.

Provide reasonable



plant layout.




appliances, loosely

following Codes of Practice

and Industry Guidance.

Provide relevant



plant layout.


layout arrangement without


appliances, loosely



Provide limited



plant layout.


plant layout arrangement.


the design of plant layout.


35

Category Excellent

(A to A-)

Good

(B+ to B)

Average

(C+ to C)

Below Average

(D+ to D)

Failure

(F)

Marks

Waste Treatment (10)

Identified wastes in the

design

Appropriate regulatory

limits

Block flow diagram to

treat all wastes

Reasonable

justification in

selecting treatment

method

Properly identify and

classify major waste along

with flow rate and nature

(i.e. phase, characteristics,

and compositions).

State appropriate regulation

limit.

Propose pollution control,

waste disposal and

treatment strategy based on

ethical and statutory

requirements, with sound

technical background and

practical implementation,

supported with block flow

diagram that shows the

major equipment

Identify and classify some

of the major waste along



and compositions).


limit.


waste disposal and



requirements, with relevant





major equipment


of the major waste without

adequate information (i.e.

phase, characteristics, and

compositions).


limit.


waste disposal and



requirements, with limited



and insufficient block flow

diagram





compositions).

State irrelevant regulation

limit.


waste disposal and



requirements, with

inadequate

technical/practical

background and insufficient

block flow diagram

Do not identify and classify

the major wastes.


regulations.

Lack or show errors in the

development of pollution

control, waste disposal and

treatment strategy for the

process or lack or provide

wrong justification behind

the development.


36

Category Excellent

(A to A-)

Good

(B+ to B)

Average

(C+ to C)

Below Average

(D+ to D)

Failure

(F)

Marks

Process Economics and

Cost Estimation (10)

Capital Cost

Estimation

Commercial

Implementation

Economic Estimation

Accuracy

Provide a complete

calculation for capital items,

operating costs and


plant with reasonable and

practical assumptions.

Provide calculation for

capital items, operating

costs and economic

potential of the plant with

relevant assumptions.



costs and economic


limitedly justified

assumptions and minor

errors.

Provide incomplete


operating costs and


plant with very limitedly

justified assumptions and

minor error.

Lack or wrong technical

assumptions in the


operating costs and


plant.

Use the latest costs and

prices in the detailed

economic calculation.

Use relevant costs and






Use reasonable costs and

prices but with no proper

research in the detailed


Use unreasonable and

wrong values for costs and



Provide sound technical and

practical recommendation

as to the commercial

implementation of the

process.

Provide reasonable

technical and practical

recommendation as to the

commercial implementation

of the process.

Provide relevant technical

and practical



of the process.

Provide poor technical and




process.

Lack technical and practical



of the process.

Prove 25% accuracy using

the Detailed Factorial

Method.

Show 25-35% accuracy

using the Detailed Factorial

Method.

Prove 35-45% accuracy


Method.



Method.

Show 100% error using the

Detailed Factorial Method.


Form PDP II-3

37

Category Excellent

(A to A-)

Good

(B+ to B)

Average

(C+ to C)

Below Average

(D+ to D)

Failure

(F)

Marks

Conclusion and

Recommendation (10)

Relevancy to the

objectives

Suggested future

works on feasibility of

design

Relate the outcome from the

project to the objectives

clearly.

Discuss the feasibility of the

design thoroughly, or

design has practical,

technical and economic

feasibility.

Provide technical and

constructive suggestions to

improve the design.


project to the objectives.


design, or design has

limited practical, technical

and economic feasibility.

Provide suggestions to

improve the design.



limitedly.


design limitedly, or design

has limited practical,

technical and economic

feasibility.

Provide limited suggestions

to improve the design.



insufficiently.


design insufficiently, or

design has very limited

practical, technical and

economic feasibility.

Provide irrelevant

suggestions to improve the

design.

Do not relate the outcome

from the project to the

objectives, or the outcome

does not match the

objectives.

Did not discuss feasibility

of the design. Design is not

feasible.

Do not provide technical

and constructive

suggestions to improve the

design.


38

Category Excellent

(A to A-)

Good

(B+ to B)

Average

(C+ to C)

Below Average

(D+ to D)

Failure

(F)

Marks

Others (20)

Compliance to standard

guideline

Neatness and consistency

in formatting style

References are quoted

and listed appropriately

Proper English Usage

Writing Skill

Follows the formatting

style stated by the

guidelines accurately.


style stated by the

guidelines to some extent.

Follows an acceptable

formatting style though not

as per the guidelines.

Uses an inconsistent

formatting style.

Not following any standard

formatting style.

Follows the method of

referencing stated by the





Follows acceptable method

of referencing though not


Provide an inconsistent

method of referencing but

not as per the guidelines

provided.

No proper method of

referencing.

The report is very well

structured and provides

good flow of information

and discussion.

The report is well



(with very minimum

disorganization).

The report is structured

with minimum

disorganization.

The report is not structured

with obvious

disorganization.

No organization of content.

The content is

comprehensive, easy to be

understood with very

minimal spelling or

grammatical errors.

The content is easy to be

understood with minimal

spelling or grammatical

errors.


understood with some


errors.

The content is slightly

difficult to be understood

with significant amount of

spelling and grammatical

errors.

The content is difficult to

be understood with

significant amount of


errors.


Comments:

.………………………….

Supervisor’s signature

Name : ______________________________________________________ Date : ____________________

39

FYDP II – INDIVIDUAL REPORT SCORE SHEET FOR SUPERVISOR


Student’s Name: _______________________________________________ Student’s ID: _________

Group No: ______ Major Equipment: ________________________________________________________________________________________________________

Minor Equipment I: _______________________________________________ Minor Equipment II: ________________________________________

Minor Equipment III: _______________________________________________ Minor Equipment IV: ________________________________________

Programme: Chemical Engineering

Category Excellent

(A to A-)

Good

(B+ to B)

Average

(C+ to C)

Below Average

(D+ to D)

Failure

(F)

Marks

Process design of major

equipment (20)

Design methodology

Basis of selection

Sample calculation

Specification sheet



selection of process design

for major equipment.

The individual follows all

the parameters

(methodology, selection,

sample calculation and

specification sheets)

regarding process design of

major equipment


limited scientific

justification on selection of

process design for major

equipment.

The individual follows

parameters (methodology,

selection, sample

calculation and



major equipment






some of the parameters





major equipment




equipment.

The individual follows few


selection, sample

calculation and



major equipment


justification selection of


equipment

The individual does not

follow parameters





major equipment


Form PDP II-5

40

Category Excellent

(A to A-)

Good

(B+ to B)

Average

(C+ to C)

Below Average

(D+ to D)

Failure

(F)

Marks

Minor Equipment I (10)

Design methodology

Specification sheet


comprehensive technical

description of minor

equipment I with design

methodology and

specification sheet

Provide comprehensive

technical description of

minor equipment I with

design methodology and

specification sheet





specification sheet




methodology and few errors

in specification sheet




methodology


Minor Equipment II

(10)

Design methodology

Specification sheet




equipment II with design

methodology and

specification sheet



minor equipment II with


specification sheet





specification sheet









methodology and

specification sheet


Minor Equipment III

(10)

Design methodology

Specification sheet





methodology and

specification sheet





specification sheet





specification sheet









methodology


Minor Equipment IV

(10)

Design methodology

Specification sheet





methodology and

specification sheet





specification sheet





specification sheet









methodology


41

Category Excellent

(A to A-)

Good

(B+ to B)

Average

(C+ to C)

Below Average

(D+ to D)

Failure

(F)

Marks

Mechanical design of

equipment (20)

Material selection

Pressure vessel thickness

calculations

Combined stress for tall

columns

Flanges, nozzles, skirts

and supports


scientific justification of

selection of material

Clearly demonstrate the

correct calculations for

pressure vessel thickness

and combined stress for tall

columns with citation

support

Provide a complete

calculations and mechanical

specification of sheet

equipment and all

supporting component

(Flanges, nozzles, skirts

and other supports)


limited scientific

justification of the selection

of material


calculations for pressure

vessel thickness and

combined stress for tall

columns with text book

support

Provide incomplete


specification sheet of

equipment and all



and other supports).


scientific justification of the


.

Show limited calculations

for pressure vessel

thickness and combined

stress for tall columns

Provide incomplete



equipment and most of its



and other supports)



of material


minimum technical




columns

Provide incomplete



equipment and few of its






of material

Lack or show wrong




columns.

Provide an incomplete or

wrong calculations and

mechanical specification

sheet of equipment and its

component (Flanges,

nozzles, skirts and other

supports)


Drawing of equipment

(10)

standards, dimensioning

and neatness

The equipment drawing

follows complete standards

with absolute dimensioning

of the equipment and

neatness.


follows standards with

absolute dimensioning of

the equipment and neatness.




the equipment.


does not follow complete

standards with

dimensioning of the

equipment.

The equipment drawing is

difficult to understand with

dimensioning errors of the

equipment with no

neatness.


42

Category Excellent

(A to A-)

Good

(B+ to B)

Average

(C+ to C)

Below Average

(D+ to D)

Failure

(F)

Marks

Operating procedure

(10)

Start-up, operating and

shutdown procedures

Provide a complete

description of Start-up,

operating and shutdown

procedures of the

equipment with clear


Provide a description of


shutdown procedures of the

equipment with relevant





equipment with limitedly


minor errors




procedures of the



minor errors




procedures of the

equipment


Others (10)


guideline


in formatting style




Writing Skill


style stated by the








and discussion.

The content is



minimal spelling or

grammatical errors


style stated by the




guidelines to some extent

The report is well



(with very minimum

disorganization).




errors.





of referencing though not as

per the guidelines.


with minimum

disorganization.




errors.


formatting style.




provided.


with obvious

disorganization





errors.


formatting style.

No proper method of

referencing



be understood with



errors.


TOTAL /90

Comments:

.………………………….………………………


Name : ____________________________________________ Date : ____________________

43

PDP II – EVALUATION OF FINAL ORAL PRESENTATION (GROUP)

(To be completed by Supervisor/External Examiner)


Category Excellent

(A to A-)

Good

(B+ to B)

Average

(C+ to C)

Below Average

(D+ to D)

Failure

(F)

Marks

Process Design (25)

Process Operating Mode

Justification

Input–Output Structure

of the Flow sheet



selection of process

operating mode and

development of input-

output structure.


limited scientific


process operating mode and


output structure.



selection of process

operating mode and


output structure.





output structure.





output structure.



knowledge with latest

literature support.



knowledge with textbook

support.



knowledge.

Show very limited technical

application with minor error

of fundamental knowledge.

Lack or show wrong



Reactor Design and

Reactor Network

Synthesis

Separation System -

Type of Separator

Justification and

Operating conditions

Heat Integration - Heat

Exchanger Network;

Utilities



design and network

synthesis for reactor and

separation systems.



knowledge with latest

literature support.

Provide clear explanation

on the design of heat

exchanger network and the

saving in utilities, based on

the heat integration study.

Provide two PFDs which

clearly show the differences

made via the

implementation of heat

integration.


limited scientific

justification on design and

network synthesis for

reactor and separation

systems.



knowledge with textbook

support.

Provide limited explanation





Provide two PFDs which

clearly show the differences

made via the


integration.



design and network

synthesis for reactor and

separation systems.



knowledge.

Provide limited explanation





Provide only one PFD but

correctly show all the


integration.





systems.


minimum technical


knowledge.

Provide very limited or

wrong explanation on the

design of heat exchanger

network and the saving in

utilities, based on the heat

integration study.

Provide only one PFD but

with errors on the


integration.





systems.

Lack or show wrong




explanation on the design of

heat exchanger network and

the saving in utilities, based

on the heat integration

study.

No information or evidence


heat integration.

(Marks: 20-25) (Marks: 16.2-19.9) (Marks: 12.5-16.1) (Marks: 10-12.4) (Marks: 0.0-9.9)

Form PDP II-6

44

Category Excellent

(A to A-)

Good

(B+ to B)

Average

(C+ to C)

Below Average

(D+ to D)

Failure

(F)

Marks

Instrumentation and


Basic control strategy

Piping and

Instrumentation Diagram

(P&ID)



the development of







literature support.

Provide a summary of

control requirements,



table form.


limited scientific


development of







support.





table form.



the development of






strategy.





table form.



development of




minimum technical


knowledge.





table form.



development of



Lack or show wrong




of control requirements,



table form.



Standard) that clearly shows

the control system

thoroughly with technical

accuracy.



Standard) that clearly shows

the control system with

some technical accuracy.



Standard) that do not show

the control system

thoroughly (incomplete).



system, with some technical

errors and not according to

PETRONAS Technical

Standard.



control strategy.

(Marks: 12.0-15.0) (Marks: 9.8-11.9) (Marks: 7.5-9.6) (Marks: 6.0-7.4) (Marks: 0.0-5.9)

45

Category Excellent

(A to A-)

Good

(B+ to B)

Average

(C+ to C)

Below Average

(D+ to D)

Failure

(F)

Marks

Safety and Loss

Prevention (15)

Hazard and Operability

Studies (HAZOP)

Plant Layout



HAZOP analysis on

THREE (3) nodes


major equipment.



on THREE (3) nodes



minor errors.


incomplete HAZOP




minor errors.


incomplete HAZOP




major errors.

Lack or provide

wrongHAZOP analysis.

Provide a thorough HAZOP

worksheet that clearly


technical accuracy.

Provide a HAZOP



technical accuracy.




minor technical errors.




major technical errors.



HAZOP study.


scaled plant layout


routes and safety



Industry Guidance.


practical



plant layout.






Industry Guidance.

Provide reasonable



plant layout.




appliances, loosely



Provide relevant



plant layout.




appliances, loosely



Provide limited



plant layout.






46

Category Excellent

(A to A-)

Good

(B+ to B)

Average

(C+ to C)

Below Average

(D+ to D)

Failure

(F)

Marks


Identification of Major

Waste

Identification of

Regulation limit

Appropriate Method of

Treatment and Basic

flow diagram





and compositions).


limit.


waste disposal and








major equipment.





and compositions).


limit.


waste disposal and








major equipment.





compositions).


limit.


waste disposal and







diagram.





compositions).


limit.


waste disposal and



requirements, with

inadequate

technical/practical

background and insufficient

block flow diagram.

Do not identify and classify

the major wastes.


regulations.







the development.




Capital Estimation

Operating Cost

Economic Potential

Provide a complete


operating costs and






costs and economic





costs and economic


limitedly justified


errors.

Provide a calculation for


costs and economic


very limitedly justified


error.


assumptions in the


operating costs and


plant.

Provide sound technical and




process.

Provide reasonable




of the process.


and practical



of the process.





process.

Lack technical and practical



of the process.



Method.



Method.



Method.



Method.




Form PDP II-3

47

Category Excellent

(A to A-)

Good

(B+ to B)

Average

(C+ to C)

Below Average

(D+ to D)

Failure

(F)

Marks

Team Work (10)

Ability to work with others

in order to provide best

performance/presentation.

Completed the presentation

within the time given. Show

high coordination of tasks

and smooth transition

between members.

Completed the presentation

within the time given. Show

good coordination of tasks

and good/smooth transition

between members.

Exceed the time given to

complete the presentation

(1-2 minutes). Show

moderate coordination of

tasks and smooth transition

between members.

Exceed the time given to

complete the presentation

(3-4 minutes). Show no

coordination of tasks and

irregular/unsmooth

transition between

members.

Did not complete the

presentation within the time

given (more than 5

minutes). No clear division

or coordination of tasks

among members.

Highly awareness

/attentiveness between

members.

Good awareness

/attentiveness between

members.

Members are aware and

focus with other member’s

tasks.

Low focus /attentiveness

between members.

Members are not focus and

attentive towards other

members.

(Marks: 8-10)

(Marks: 6.5-7.9)

(Marks: 5.0-6.4)

(Marks: 4.0-4.9)

(Marks: 0.0-3.9)

Comments:

.………………………….………………………

Supervisor/Examiner’s signature

Name : ______________________________________________________ Date : ______________________

48

FYDP II – EVALUATION OF FINAL ORAL PRESENTATION (INDIVIDUAL)





Category Excellent

(A to A-)

Good

(B+ to B)

Average

(C+ to C)

Below Average

(D+ to D)

Failure

(F)

Marks

Non-verbal

Communication (20)

Professionalism:

appearance, Facial

expression;

confidence,

enthusiasm

Gesture: Eye Contact,

Pauses

The oral presentation is

presented in complete

professional way regarding

the dressing, expressions,

enthusiasm and confidence

The non-verbal

communication takes no

pauses with full eye contact


presented in professional

way regarding the dressing,

expressions, enthusiasm and

confidence

The non-verbal

communication takes few

pauses with full eye contact


tried to present in

professional way regarding

the dressing, expressions,

enthusiasm and confidence

The non-verbal

communication takes few

pauses with most of the eye

contact


tried to present in

professional way but with

lack of confidence and

enthusiasm

The non-verbal

communication lacks eye

contact with several pauses

during presentation.

The oral presentation does

not satisfy professionalism

regarding the dressing,

expressions, enthusiasm and

confidence

The non-verbal

communication does not

satisfy the eye contact with

several pauses during

presentation.


Form PDP II-7

49

Category Excellent

(A to A-)

Good

(B+ to B)

Average

(C+ to C)

Below Average

(D+ to D)

Failure

(F)

Marks

Clarity of presentation

(40)

Vocal Clarity and

Quality: volume, rate,

articulation,

pronunciation natural,

conversational, emphasis

Fluency and choice of

words: (using language

clearly and accurately)

Pronunciation,

articulation

Continuity of

Presentation

Use of aids (graphs,

diagrams, objects etc)

Organization: logical

flow, time management

The presentation shows the

clear vocal clarity with

quality professional

presenting skills

The choice of words are

perfect with fluent

consistency

The presentation covers all

the relevant aids (graphs,

diagrams and objects) in

organized form

.

The presentation skills

show vocal clarity with

clear professionalism


good with fluent

consistency

The presentation covers

relevant aids (graphs,

diagrams and objects) with

organized form

The presentation shows

most of the vocal clarity

with professional presenting

skills


satisfactory with fluent

consistency

The presentation covers

most of the relevant aids

(graphs, diagrams and

objects) with deficient in

organized form

.

The presentation shows the

lack in vocal clarity with

satisfactory presenting

skills


satisfactory with lack in

fluent consistency

The presentation covers few

relevant aids (graphs,

diagrams and objects) with

deficient in organized form

The presentation does not

show the vocal clarity with

unsatisfactory presenting

skills


unsatisfactory with no

fluent consistency

The presentation does not

cover any relevant aids

(graphs, diagrams and

objects) with deficient in

organized form

(Marks: 32-40)

(Marks: 26-31.9)

(Marks: 20-25.9)

(Marks: 16.0-19.9)

(Marks: 0.0-15.9)

Thoroughness of the

Subject (20)

Knowledge of the subject

Technical and factual

accuracy; Grasp of

subject

The individual shows full

hold on the topic and

possess a deep knowledge

of the subject with technical

aspects

The individual has hold on

the topic and possess a deep

knowledge of the subject

with technical aspects

The individual has some

hold on the topic and

possess some knowledge of

the subject with few

technical aspects

The individual has

satisfactory hold on the

topic and possess a

acceptable knowledge of

the subject with few

technical aspects


show grasp on the topic and

possess unsatisfactory

knowledge of the subject


50

Category Excellent

(A to A-)

Good

(B+ to B)

Average

(C+ to C)

Below Average

(D+ to D)

Failure

(F)

Marks

Questions and Answers

(20)

Creativity – use of

example

Convincing Answer,

Showing creativity and

Innovativeness

Ability to anticipate and

answer questions

Ability to maintain good

relationship with

questioners

The individual clearly

answered all the questions

with convincing knowledge

using relevant examples.

The individual shows full

anticipation and maintain

very good relation with the

questioners

The individual answered all

the questions with

convincing knowledge

using relevant example.

The individual shows

anticipation and maintain

very good relation with the

questioners

The individual answered

most of the questions with

satisfactory knowledge

using relevant example.


satisfactory anticipation and

maintain good relation with

the questioners

The individual answered

few questions with

satisfactory knowledge

using example.


satisfactory anticipation and

maintain normal relation

with the questioners


answered any questions

with convincing knowledge

with irrelevant examples.


show anticipation and does

not maintain good relation

with the questioners


Comments:

.………………………….………………………


Name : ______________________________________________________ Date : ______________________

51

EVALUATION FORM PDP II – GROUP REPORT (DESIGN)

(PROCESS CONTROL STRATEGY AND P&ID)

(To be completed by Internal Expert)


Category Excellent

(A to A-)

Good

(B+ to B)

Average

(C+ to C)

Below Average

(D+ to D)

Failure

(F)

Marks

Chapter 4:

Instrumentation and


P&ID in A1 size

Reasonable justification

on control requirements –

basic and advanced

Appropriate numbering

of process equipment and

pipelines

Appropriate symbols

used – PTS or other

standards



the development of







literature support.

Provide a complete

summary of control


equipment, possible




limited scientific


development of







support.


summary of control


equipment, possible





the development of






strategy.


summary of control

requirements for limited

number of equipment,



table form.



development of




minimum technical


knowledge.


summary of control

requirements for few

number of equipment with

minor error, possible





development of



Lack or show wrong




of control requirements or

with major errors, possible



Provide a PID (drawn

based on PETRONAS

Technical Standard) that

clearly shows the control

system thoroughly with

technical accuracy.


based on PETRONAS

Technical Standard) that

clearly shows the control

system with some technical

accuracy.


based on PETRONAS

Technical Standard) that do

not show the control

system thoroughly

(incomplete).



system, with some

technical errors and not

according to PETRONAS

Technical Standard.



control strategy.


Form PDP II-8

52

Category Excellent

(A to A-)

Good

(B+ to B)

Average

(C+ to C)

Below Average

(D+ to D)

Failure

(F)

Marks

Others (10)


guideline


in formatting style




Writing Skill


style stated by the



style stated by the






formatting style.


formatting style.













provided.

No proper method of

referencing.




and discussion.

The report is well



(with very minimum

disorganization).


with minimum

disorganization.


with obvious

disorganization.


The content is



minimal spelling or

grammatical errors.




errors.




errors.





errors.


be understood with



errors.


TOTAL /30

Comments:

.………………………

Examiner’s signature

Name : ______________________________________________________ Date : ______________________

53

EVALUATION FORM PDP II – GROUP REPORT (DESIGN) FOR INTERNAL EXPERT

(PROCESS ECONOMICS AND COST ESTIMATION)



Category Excellent

(A to A-)

Good

(B+ to B)

Average

(C+ to C)

Below Average

(D+ to D)

Failure

(F)

Marks

Chapter 7:



Capital Cost Estimation

Commercial

Implementation

Economic Estimation

Accuracy

Provide a complete

calculation for capital

items, operating costs and






costs and economic





costs and economic


limitedly justified


errors.

Provide incomplete




plant with very limitedly


minor error


assumptions in the




plant.




Use relevant costs and






Use reasonable costs and

prices but with no proper

research in the detailed


Use unreasonable and

wrong values for costs and



Provide sound technical

and practical


commercial


process.

Provide reasonable



commercial


process.


and practical


commercial


process.





process.

Lack technical and




process.



Method.


using the Detailed

Factorial Method.


using the Detailed

Factorial Method.


using the Detailed

Factorial Method.




Form PDP II-3

Form PDP II-9

54

Category Excellent

(A to A-)

Good

(B+ to B)

Average

(C+ to C)

Below Average

(D+ to D)

Failure

(F)

Marks

Others (10)


guideline

Neatness and

consistency in

formatting style




Writing Skill


style stated by the



style stated by the



formatting style though

not as per the guidelines.


formatting style.

Not following any

standard formatting style.







Follows acceptable

method of referencing

though not as per the

guidelines.




provided.

No proper method of

referencing.




and discussion.

The report is well



(with very minimum

disorganization).


with minimum

disorganization.


with obvious

disorganization.

No organization of

content.

The content is



minimal spelling or

grammatical errors.




errors.




errors.





errors.

The content of the report is




errors.


TOTAL /30

Comments:

.………………………


Name : ______________________________________________________ Date : ______________________

55

EVALUATION FORM PDP II – GROUP REPORT (DESIGN) FOR INTERNAL EXPERT

(SAFETY AND LOSS PREVENTION)



Category Excellent

(A to A-)

Good

(B+ to B)

Average

(C+ to C)

Below Average

(D+ to D)

Failure

(F)

Marks

Chapter 5:

Safety and Loss

Prevention (20)

Reasonable selection of

study nodes for HAZOP

Scaled plant layout in A3

size


on safety aspects

Appropriate standard and

symbols



HAZOP analysis on

THREE (3) nodes


major equipment.



on THREE (3) nodes



minor errors.


incomplete HAZOP




minor errors.


incomplete HAZOP




major errors.


HAZOP analysis.

Provide a thorough


clearly shows the study

results with technical

accuracy.

Provide a HAZOP



technical accuracy.



shows the study results

with minor technical errors.



shows the study results

with major technical errors.



HAZOP study.


scaled plant layout


routes and safety



Industry Guidance.


practical



plant layout.






Industry Guidance.

Provide reasonable



plant layout.




appliances, loosely

following Codes of

Practice and Industry

Guidance.

Provide relevant



plant layout.




appliances, loosely

following Codes of

Practice and Industry

Guidance.

Provide limited



plant layout.






Form PDP II-10

56

Category Excellent

(A to A-)

Good

(B+ to B)

Average

(C+ to C)

Below Average

(D+ to D)

Failure

(F)

Marks

Others (10)


guideline


in formatting style




Writing Skill


style stated by the



style stated by the






formatting style.


formatting style.













provided.

No proper method of

referencing.




and discussion.

The report is well



(with very minimum

disorganization).


with minimum

disorganization.


with obvious

disorganization.


The content is



minimal spelling or

grammatical errors.




errors.




errors.





errors.





errors.


TOTAL /30

Comments:

.………………………


Name : ______________________________________________________ Date : ______________________

57

EVALUATION FORM PDP II – GROUP REPORT (DESIGN)

(WASTE TREATMENT STRATEGY)



Category Excellent

(A to A-)

Good

(B+ to B)

Average

(C+ to C)

Below Average

(D+ to D)

Failure

(F)

Marks

Chapter 6:


Identified wastes in the

design

Appropriate regulatory

limits

Block flow diagram to

treat all wastes


in selecting treatment

method





and compositions).

State appropriate

regulation limit.


waste disposal and








major equipment





and compositions).

State appropriate

regulation limit.


waste disposal and








major equipment





compositions).

State appropriate

regulation limit.


waste disposal and







diagram





compositions).


limit.


waste disposal and



requirements, with

inadequate

technical/practical

background and

insufficient block flow

diagram

Do not identify and

classify the major wastes.


regulations.







the development.


Form PDP II-11

58

Category Excellent

(A to A-)

Good

(B+ to B)

Average

(C+ to C)

Below Average

(D+ to D)

Failure

(F)

Marks

Others (10)


guideline


in formatting style




Writing Skill


style stated by the



style stated by the






formatting style.


formatting style.













provided.

No proper method of

referencing.




and discussion.

The report is well



(with very minimum

disorganization).


with minimum

disorganization.


with obvious

disorganization.


The content is



minimal spelling or

grammatical errors.




errors.




errors.





errors.


difficult to be under stood



errors.


TOTAL /30

Comments:

.………………………


Name : ______________________________________________________ Date : ______________________

59

FYDP II – INDIVIDUAL REPORT SCORE SHEET FOR INTERNAL EXPERT



Group No: ______ Major Equipment: ________________________________________________________________________________________________________

Minor Equipment I: _______________________________________________ Minor Equipment II: ________________________________________

Minor Equipment III: _______________________________________________ Minor Equipment IV: ________________________________________


Category Excellent

(A to A-)

Good

(B+ to B)

Average

(C+ to C)

Below Average

(D+ to D)

Failure

(F)

Marks

Process design of major

equipment (20)

Design methodology

Basis of selection

Sample calculation

Specification sheet





The individual follows all

the parameters





major equipment


limited scientific



equipment.



selection, sample

calculation and



major equipment






some of the parameters





major equipment




equipment.

The individual follows few


selection, sample

calculation and



major equipment




equipment


follow parameters





major equipment


Form PDP II-12

60

Category Excellent

(A to A-)

Good

(B+ to B)

Average

(C+ to C)

Below Average

(D+ to D)

Failure

(F)

Marks

Minor Equipment I (10)

Design methodology

Specification sheet





methodology and

specification sheet





specification sheet





specification sheet









methodology


Minor Equipment II

(10)

Design methodology

Specification sheet





methodology and

specification sheet





specification sheet





specification sheet









methodology and

specification sheet


Minor Equipment III

(10)

Design methodology

Specification sheet





methodology and

specification sheet





specification sheet





specification sheet









methodology


Minor Equipment IV

(10)

Design methodology

Specification sheet





methodology and

specification sheet





specification sheet





specification sheet









methodology


61

Category Excellent

(A to A-)

Good

(B+ to B)

Average

(C+ to C)

Below Average

(D+ to D)

Failure

(F)

Marks

Mechanical design of

equipment (20)

Material selection

Pressure vessel thickness

calculations

Combined stress for tall

columns

Flanges, nozzles, skirts

and supports


scientific justification of



correct calculations for

pressure vessel thickness

and combined stress for tall

columns with citation

support

Provide a complete


specification of sheet

equipment and all



and other supports)


limited scientific


of material





columns with text book

support

Provide incomplete



equipment and all





scientific justification of the


.

Show limited calculations

for pressure vessel

thickness and combined

stress for tall columns

Provide incomplete



equipment and most of its



and other supports)



of material


minimum technical




columns

Provide incomplete



equipment and few of its






of material

Lack or show wrong




columns.

Provide an incomplete or

wrong calculations and

mechanical specification

sheet of equipment and its

component (Flanges,

nozzles, skirts and other

supports)


Drawing of equipment

(10)

standards, dimensioning

and neatness


follows complete standards

with absolute dimensioning

of the equipment and

neatness.




the equipment and neatness.




the equipment.


does not follow complete

standards with

dimensioning of the

equipment.

The equipment drawing is

difficult to understand with

dimensioning errors of the

equipment with no

neatness.


62

Category Excellent

(A to A-)

Good

(B+ to B)

Average

(C+ to C)

Below Average

(D+ to D)

Failure

(F)

Marks

Operating procedure (10)


shutdown procedures

Provide a complete



procedures of the

equipment with clear





equipment with relevant







minor errors




procedures of the



minor errors




procedures of the

equipment


Others (10)


guideline


in formatting style




Writing Skill


style stated by the








and discussion.

The content is



minimal spelling or

grammatical errors


style stated by the




guidelines to some extent

The report is well



(with very minimum

disorganization).




errors.





of referencing though not as

per the guidelines.


with minimum

disorganization.




errors.


formatting style.




provided.


with obvious

disorganization





errors.


formatting style.

No proper method of

referencing



be understood with



errors.


TOTAL /90

Comments:

.………………………….………………………

Internal expert’s signature

Name : ____________________________________________ Date : ____________________

Plant Design II Guidelines (May 2015)

Documents

Transcript of Plant Design II Guidelines (May 2015)